How to align cost savings with sustainability

Businesses are facing a tough choice. Do they swallow rising energy prices themselves, or pass on the cost to customers? There’s no easy answer, but there is a way to ease the pain. Operating correctly aligned machines with the most energy-efficient bearing solutions can reduce running costs, and shrink energy bills. Yet research suggests over 50% of machines and industrial equipment are currently running out of alignment.
 

Misalignment typically occurs when coupled shafts are positioned so that their gaps or offsets are beyond acceptable limits. The consequence is that shafts run off-centre – causing high loads, generating excessive heat, and leading to greater energy consumption.

But there’s no need to wait for the next energy bill to reveal if misalignment is occurring.

Signs might include increased temperature, high vibration, loose coupling bolts, or excessive lubricant leakage at bearing seals. Machines or systems showing these symptoms will almost certainly be using more power than if they were aligned correctly and running efficiently.

And with the right tools, correct alignment is easy.

Up to 17% savings

Users of NSK’s advanced laser alignment tools for shafts and belts have identified energy savings of up to 17%.

And correct alignment not only cuts power consumption but also reduces wear on important machine components like seals and couplings. This minimises machine downtime and maximises throughput in turn.

With NSK’s laser alignment tools, achieving perfect alignment is quick and easy – just like the ROI that results.
 

Be a carbon-zero hero

As industry tries to reduce its energy costs, it’s also striving for net-zero carbon emissions.

And with electric motors and associated systems accounting for more than 40% of global electricity consumption, they’re an obvious target for some fairly easy wins.

The wide range of energy-efficient bearings available from NSK not only saves money – by reducing machine running costs – but also cuts CO₂ emissions and contributes to more sustainable industrial operations.

The NSK series of deep groove ball bearings, for example, generates up to 80% less energy loss when deployed in electric motors. Compared with conventional deep groove products, these high-efficiency bearings produce 60% less friction with a steel cage, and 80% less with a plastic one.

NSK’s EA7 grease also increases energyefficiency, by reducing internal friction. At the same time, it doubles the service interval of electric motors, and provides enhanced lubricating properties when micro-vibrations are present. Alongside optimised grease fill, this low-viscosity, friction-reduced lubricant provides the ideal solution for any manufacturer wanting to reduce torque, minimise power loss and cut carbon emissions.

Look: don’t touch

Engineers designing energy-efficiency drive systems should always look closely at rolling bearings. That’s because it’s all too easy to compromise drive efficiency, through the friction inherent in conventional seal contact.

NSK’s non-contact seal technology products, on the other hand, ensure efficient sealing without increasing frictional torque or operating temperatures.

Based on concepts such as optimised raceway geometry and special sealing, NSK has also developed several series of bearings that deliver significantly lower friction characteristics.

These low-friction bearings can provide significant benefits in, for example, the automotive industry, where OEMs are seeking energy-efficiency gains from on-vehicle drive mechanisms. In other sectors (such as washing machine production) a favourable efficiency class often leads to higher sales – and this type of bearing also reduces operational noise and heat generation, which helps to extend service life.

Innovation in a bearing

The innovative technology of many NSK bearings makes them the perfect fit for innovative industry sectors, such as electric vehicle manufacture.

NSK’s pioneering plastic bearing cage improves the high-speed rotational performance of electric vehicle motors. The cage’s lighter weight – compared with a steel version – means reduced mechanical losses. In addition, it has excellent self-lubricating properties and a low co-efficient of friction. All these factors together contribute to energy efficiency and sustainability.

NSK has also developed the world’s first bearing with a 100% plant-derived bioplastic cage. Designed for use in air conditioner fan motors, it helps reduce plastic use and power consumption.

It’s this kind of environmental and sustainability initiative which helps industry to be green – and helps businesses to keep their bottom line black.